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A Treatise on 
Roller Mill Belt Guards 



Showing How to Guard Against 
the Hazards of Exposed Belts. 
Guards of Standard Con- 
struction and Design — 
Simple, Economical 
and Fireproof 



Millers Mutual Casualty Insurance Co. 

Insurance Exchange 
Chicago 



v 



Safeguard Standards 

1. The guard must be practical and designed 
to protect an actual hazard. 

2. The guard must not conceal the parts pro- 
tected, and must not interfere with the operation 
of the machine. 

3. The guard must be of substantial construc- 
tion and made entirely of fireproof materials when 
possible. 

4. The guard should be of the removable type. 
The *" Quick-Detachable" method is recommended 
as it affords instant access to the machine and is as 
readily replaced. 



>C!.A414516 



Copyright, 1915 
Miixkrs Mi ti al Casualty Insi bahce Compact 



NOV I 1915 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 



Roller Mill Guards 

THE Milling and Grain Industry, like every great industry, should collect and 
analyze the cause and frequency of accidents peculiar to their class of business. 
The designing of guards and safety devices to prevent similar occurrences, as well 
as the steps necessary for the elimination of hazardous conditions and unsafe practices, 
must be delegated to a central bureau to secure the benefit of collective experience. 

The Millers Mutual Casualty Insurance Company realized at the outset that the 
Milling Industry was without this essential bureau and that as a result the unneces- 
sary loss occasioned by accidental injuries was taking tremendous toll with practically 
no intelligent or concerted effort to eliminate this drain upon the resources of the 
entire industry. There being no available statistics upon which to base the relative 
hazard., which was absolutely essential for the promulgation of fair and equitable rates 
and credits, this company compiled this information by recording and classifying all 
accidents in this industry which came to our attention. These statistics are an in- 
valuable aid in our Safety Campaign and form the basis of our safety bulletins and 
other safety propaganda. 

SAFETY ENGINEERING DEPARTMENT 

A Safety Engineering Department was organized and placed in charge of all acci- 
dent prevention activities. Through the statistics compiled on the cause of accidents 
occurring in our class of business, their most frequent source as well as the most haz- 
ardous conditions in the mills are ascertained. Thus every member receives the 
benefit of the experience of other members. The value of this collective experience 
to the individual member cannot be estimated. 

On the following pages is presented a set of guards for Roller Mill Belts. Approved 
guards for other various machines entering into the equipment of flour mills and grain 
elevators will be similarly treated in due course. Hazardous conditions and unsafe 
practices will be taken care of through the medium of safety bulletins. 

SAFETY INSPECTION AND INDUSTRIAL BOARD 

In view of the fact that the various State Industrial and Inspection Departments 
have been vested with wide discretionary powers as to what shaD constitute a proper 
guard, many of our members having taken up this proposition unaided, have found 
that the guards they have installed do not meet with the approval of these various 
departments. As a result, the time and money expended for this purpose was an 
absolute loss, for in most instances the guards had to be greatly altered or entirely 
reconstructed. It was with a view of avoiding this loss of time and expense that we 

[3] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 

have taken the matter up with the various State Departments and secured their 
approval on the guards shown on the following pages. Therefore, the installation of 
this guard will avoid the above mentioned difficulties. Our members can appreciate 
the assurance that the guard is of standard construction and design. 

HAZARDS OF ROLLER MILL BELTS 

The high speed of the belts and the low position of the pulleys on roller mills 
constitute one of the most hazardous conditions in the mill. 

Unless properly guarded these belts are a serious menace to the safety of the 
employes whose duties require their presence in the vicinity of these hazards. The 
opportunity is ever present to catch some part of the clothing or person when 
working near or passing by them. 

That roller mill belts are dangerous is amply proven by reference to the number 
of men that have been killed or injured by them. In every instance it has been clearly 
shown that these accidents could have been prevented had the belts been properly 
guarded. The fact that roller mill belts constitute one of the most serious hazards is 
the reason for the detailed treatment of the subject herein. 

ROLLER MILL BELT GUARDS 

The primary purpose of a guard is to prevent accidents, and in selecting a guard 
this must be the foremost consideration. Other features are desirable, but if lacking 
in the first essential the guard is valueless. There is also a psychological effect produced 
by guarding a machine which must not be lost sight of. The impression upon the 
employe that is created when guards are installed on the machine is always favor- 
able, and assists in securing his support to the safety movement. 

The guards shown on the following pages are the result of exhaustive experiments 
and careful research. They represent the most advanced ideas on proper guard con- 
struction, and will eliminate the waste and expense of experimenting with methods 
that have been proven undesirable and ineffectual. 

ACCIDENT REDUCING VALUE 

The accident reducing value of a guard is of greater import than the cost of 
installation, and is one of the most valued features to be found in the guards here 
presented. 

Every contingency possible to anticipate has been provided for, and our expe- 
rience shows that the installation of these guards will reduce roller mill belt accidents 
to a minimum, if not prevent them entirely. 

FIREPROOF 

These guards are constructed entirely of metal and are absolutely fireproof. 
Their installation does not affect the fire hazard and they are accepted by all Fire 
Insurance Companies. They have been approved by the Mutual Fire Prevention 
Bureau. 

[4] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 

PERMANENT AND INDESTRUCTIBLE 

In view of the fact that these guards are constructed entirely of metal, they are 
permanent and indestructible, so that once installed the work is done for all time. 
Their construction is simple and substantial, and cannot be injured by rough usage. 
They may be painted any color to harmonize with the color scheme or surroundings. 

OPERATION OF MACHINES UNHINDERED 

These guards will not interfere with the operation of the machines, for while 
they cover the belt, they do not enclose the working parts of the machine in such a 
manner as to interfere with its regular operation. 

ACCESSIBILITY 

By the use of our "Q-D" guard supports the guard may be lifted up from the 
floor and set aside for any repairs or adjustments. There are no screws to loosen nor 
tools of any kind required to remove the guard. It can be taken up and set aside 
instantly, so that it will not interfere with immediate access to the machine. This 
feature is one which we recommend on all guards. A guard which will render a machine 
difficult of access when access is necessary, and which will interfere with the employe 
at some time when his attention is required, ceases to operate as a guard and may 
become a source of danger. The guards presented herein act as guards at all times 
that they are required as such. They may be instantly set aside at such times as 
accessibility is required, and as quickly replaced to continue their function of guard- 
ing when this necessity is past. 

DESCRIPTION AND ILLUSTRATIONS 

On the following pages are given detailed descriptions and illustrations which will 
enable the mill owner to supply us with all of the necessary data to properly equip 
his mill. It will require but little time to furnish all of the information necessary 
to install these guards and upon receipt of the required dimensions shown on pages 11, 
13 and 14 we will be pleased to submit an estimate of the cost of these guards. 

Millers Mutual Casualty Insurance Co. 

C {-/C^-^zi^^^tCt/ Secretary. 





[5] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 



Front and End Guards 




Front Guard 

Located in Front of Belts on Adjoining 
Roller Mills as Shown on Page 10 



Q. D. Guard Support. 



End Guard 

Located on Both Sides of Passageways and on Exposed Ends of 
Roller Mills as Shown on Pages 10 and 12 



[6] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 

Materials and Construction 



T 



HE materials for these guards have been selected as the result of extended 
experiments and tests, and are recommended by us as offering the most practical 
and substantial guard construction. 

ANGLE IRON 

The frame of the guards consists of one inch angle iron bolted or riveted together. 
This material is furnished perforated on both sides and cut to size for each guard. 

GUSSETS OR CORNER PLATES 

Gussets or corner plates of sheet steel are used at the corner intersections for 
connecting the angle iron of the frame. They provide a very rigid method of con- 
struction and are furnished perforated and cut to size. Four of these plates are used 
on the front guards and sixteen on the end guards. 

EXPANDED METAL 

This material consists of a single piece of heavy sheet steel cut and expanded. 
It is considerably stronger than wire screen and costs about half as much. It will not 
unravel or weaken when cut. and also affords less resting place for dust to accumulate 
than wire screen, and it can be readily cleaned. In placing it on the guards the diagonal 
of mesh should be set vertical on the guard. This material is made in standard size 
sheets 2-4 and 28 inches wide and 8 feet long. It can be easily cut with a tinner's 
shears and can be bolted securely to the frame. 

"QUICK DETACHABLE" GUARD SUPPORTS 

These "Q-D" supports are used to render the guard removable, and consist of a 
cast iron floor plate and a steel bar leg. The floor plate is set into the floor and the leg 
is bolted to the frame. These supports are the result of experiments with various 
means of attaching the guard to the floor, and will be found to overcome many diffi- 
culties encountered with many other methods. 

SIMPLE AND SUBSTANTIAL CONSTRUCTION 

Xo special skill or equipment is necessary to construct these guards. The angle 
iron and gussets are furnished cut to size and only need be bolted or riveted together 
to complete the frame. A screwdriver and hammer are the only tools necessary for 
this work. 

After the frames are completed, the expanded metal mesh is cut to the proper 
size and bolted to the frame. In covering end guards with this material the ends 
should be cut separate instead of bending around from the front side. When this 
material is not wide enough two pieces can be fastened together by lapping about 
one inch and inserting bolts with washers on each side. 

[7] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 



"Q-D" Guard Support 



Leg, Iron bar 1J4"xiV' 



Countersunk Holes for 

Flat-Head Bolts 



Socket, Cast Iron 




Countersunk Holes for 

Flat-Head Wood Screws 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 



Quick Detachable Guard Supports 



o 



X^the opposite page is shown a cut of the " Q-D " Guard Supports to be attached 
to the legs of the guards shown on the following pages and which niay be used 
in a similar manner with anv other guard which is to be made removable. 



£>* 



The leg is a bar of cold drawn steel tapered at one end to fit the tapered hole in 
the floorplate. The holes in the legs are drilled and countersunk for attaching to 
the frame by means of bolts and forms a very rigid means for supporting the guards. 

The floor plate is an iron casting with countersunk holes for wood screws and a 
tapered hole for receiving the tapered end of the leg. Al 1 o-hieh hole is bored in the 
floor and plates set in leaving the base protrude slightly above the floor level, after 
which it is screwed or bolted to the floor. By this means the possibility of dirt or 
sweepings getting into the tapered hole and interfering with the setting of the guard 
is avoided. This floor plate is only for use when setting the guards on wooden floors. 

CONCRETE FLOORS 

When necessary to set the guards on concrete floors, we recommend that the 
guard be completed before the holes are placed in the floor for the legs. When this 
is done, attach the legs to the frame and locate the desired position of the holes in the 
floor, after which they may be cut out to fit. Babbitt metal should then be poured 
in the hole in order that the tapered end of the legs have a rigid fit. The guard can 
be blocked up before pouring the babbitt in order to secure a proper setting. 

By attaching the guard to the floor in either of the above described methods, any 
of the protected parts of the machine are instantly available when necessary to make 
repairs or adjustments of any nature. The guard is simply lifted out of the holes and 
set aside temporarily. After the work is completed, it is readily replaced without 
loosening bolts or requiring tools of any kind. 

Specify on all inquiries or orders whether guards are to be set in wood or 
concrete floors. 



[9] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 



Roller Mill Belt Guards 



Front Guards 



End Guard - 




Front View of Roller Mills, Showing Front and End Guards. For End View of End Guards see Page 12 



[10] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 



Front Guards 



ON the opposite page the front guards are shown in place in front of the belts 
on a line of rolls. This illustration gives a general idea of the proper pro- 
portions as well as showing how the guards will appear. 
They should be placed on both sides of the mills when a passageway is used, to 
protect employe from contact with the belts. The guards are attached to the floor 
with "Q-D" guard supports shown on page S which provide for instant removal of 
the guard in case of necessity. 

Where mills of various sizes are grouped together the guards should be made the 
same height for all mills: this gives a unif orm appearance and simplifies the construc- 
tion. However, when the various sizes are in separate groups the heights can be 
made to fit each group. 

These guards are regularly made in three standard heights as follows: 4 ft., 4 ft. 
6 in., and 5 ft. see dimension sheet on page 14), but other sizes can be furnished if 
desired. 

The materials for front guards can be furnished cut to size, complete ready to be 
ss erubled: or the guards can be made up ready for installation at about 40 per cent 
additional cost. On all orders or inquiries specify whether material only or complete 
guards are wanted. 

Measurements Required 

On page 14 is a dimension sheet showing the measurements required for Front 
Guards. By referring to the letter symbols in connection with the instructions below 
the subject will be self-explanatory. 

DIMENSION "A" 

Measure the distance from the outside end of the bearing on one mill to the 
outside end of the bearing on the adjoining mill - This distance should be measured 
between every mill where the front guards are to be used, as it will vary with the 
different size mills and also depending on how far apart the mills are set. 

DIMENSION "B" 

Measure the height from the floor to the top of the largest pulley on either of the 
mills for which the guard is intended. This height should be measured on every mill 
in order that any variation in size of pulleys or heights of shafts may be known. 

When requesting information on front guards the following form will furnish 
all the of necessary information. 

4 front guards — A, -23 in. : B, 43 in. 
17 front guards — A, -29 in.; B. 43 in. 
-2 front smards— A. -29 in.: B. 36 in. 



a' 



[11 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 



Roller Mill Belt Guards 




End Guard on Differential Side End Guard on Driving Side 

See Page 10 for Front View of Front and End Guards 



[12] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 



End Guards 



OX the opposite page the end guards are shown in place at the end of a line of 
Rolls. This illustration gives a general idea of the proper proportions as 
well as showing how the guards will appear. On page 10 is shown a side view 
of the end guard. 
These guards should be placed at the ends of the rolls and on both sides of passage- 
ways between the rolls. They are attached to the floor with **Q-D" guard supports 
shown on page S which provide for instant removal of the guard in case of necessity. 

The end guards on the differential side of the mills will be higher than those on 
the driving side, but in order to simplify construction it is advisable to split the dif- 
ference and make them both the same size. This gives a more uniform appearance 
and also simplifies the construction. 

These guards are regularly made in three standard heights as follows: 4 ft., 4 ft. 
6 in., and 5 ft. (see dimension sheet on page 14), but other sizes can be furnished if 
desired. 

The materials for end guards can be furnished cut to size, complete ready for 
assembling: or the guards can be made up ready for installation at about 40 per cent 
additional cost. On all orders or inquiries specify whether material only or complete 
guards are wanted. 



& 



Measurements Required 



On page 14 is a dimension sheet showing the measurements required for end 
guards. By referring to the letter symbols in connection with the instructions below 
the subject will be self-explanatory. 
DIMENSION "C" 

Measure from the outside end of the bearing on the driving side to the outside rim 
of the pulley. 
DIMENSION "D" 

Measure the distance between the outside faces of the two driving pulleys. 
DIMENSION "E" 

Measure the height from the floor to the top face of the driving pulley. 
DIMENSION "F" 

Measure from the outside end of the bearing on the differential side to the out- 
side rim of the pulley farthest away from the mill. 
DIMENSION "G" 

Measure the distance between the outside faces of the two differential pulleys. 
DIMENSION "H" 

Measure the height from the floor to the top face of the differential pulleys. 

When requesting information on end guards the following form will furnish all 
the necessary information. 

2 end guards — C, 13 in.; D, 48 in., E, 49 in. 
5 end guards — C, 13 in.: D, 4-2 in., E, 46 in. 

3 end guards — F, 15 in.; G, 49 in., H, 49 in. 
7 end guards — F, 18 in.; G, 49 in., H, 52 in. 

[13] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 

Dimension Sheet for Roller Mill 
Belt Guards 



H 



Sejrmi 



MILL 



Bearing 



kF- 



A 



Beariry 



MILL 



Floor Plan of Adjoining Roller Mills 



Floors 



B 




Bearu 



% 




1 




c 




I 


- 


Cj 







Front Elevation of Adjoining Roller Mills 

Dimensions "A" and "B" are for Front Guards Only. Dimensions "C-D-E" are for End Guards on Driving Side 
of Mill. Dimensions "F-G-H" are for End Guards on Differential Side of Mill 



[14] 



MILLERS MUTUAL CASUALTY INSURANCE COMPANY 



w 



Conclusion 

HILE the subject treated within these pages deals principally with Roller 
Mill Guards, the same type of guards can be used for other places about 
the mill that require guarding. 



While there are standard sizes for Roller Mill Guards, the materials will readily 
adapt themselves to any size. We will be pleased to quote the net cost on any size 
guard upon receipt of specifications. 

Cost of Materials 

By handling the guard materials on a quantity basis and having our own machinery 
for manufacturing, we can save our members from 50 to 60 per cent in the cost of the 
guards as compared with the prices charged by others. This is a part of our policy 
of "Service to Members" and is concrete evidence that we are meeting this obligation. 
The guards and materials are supplied at net cost, and to our members it is virtually 
gratis, for the credits on the insurance rate more than offset the initial cost in a short 
time. 



Millers Mutual Casualty Insurance Co. 

Chicago 



[15 1 



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